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V2403-M-T
Kubota V2403-M-T User Manual
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M-3
03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM
DIESEL ENGINE
[3]
HALF-FLOATING
HEAD COVER
The rubber packing
is fitted in to maintain the cylinde
r
head cover
0.5 mm (0.02 in.)
or so off the cylinder head
.
This arrangement helps re
duce noise coming from the
cylinder head
.
W1013327
(1)
Cylinder Head Cover
(2)
Rubber Packing
KiSC issued 07, 2008 A
73
75
Table of Contents
Default Chapter
3
Before Servicing and Repairing
3
Safety First
3
Specifications
7
Dimensions
18
Wiring Diagram
24
Table of Contents
25
1 Engine Identification
26
Model Name and Engine Serial Number
26
Month of Manufacture
27
E3B Engine
28
Cylinder Number
28
2 General Precautions
29
3 Maintenance Check List
30
4 Check and Maintenance
33
Daily Check Points
33
Checking Engine Oil Level
33
Checking and Replenish Coolant
34
Check Points of Initial 50 Hours
35
Changing Engine Oil
35
Replacing Oil Filter Cartridge
36
Check Points of Every 50 Hours
37
Checking Fuel Hoses and Clamp Bands
37
Check Points of Every 100 Hours
38
Cleaning Air Cleaner Element
38
Cleaning Fuel Filter
38
Checking Battery Electrolyte Level
38
Fan Belt Damage and Wear
39
Check Points of Every 150 Hours
40
Changing Engine Oil for 90 MM Depth Oil Pan
40
Replacing Oil Filter Cartridge for 90 MM Depth Oil Pan
41
Check Points of Every 200 Hours
42
Changing Engine Oil for 124 MM Depth Oil Pan
42
Replacing Oil Filter Cartridge for 124 MM Depth Oil Pan
44
Checking Radiator Hoses and Clamp Bands
44
Checking Intake Air Line
45
Check Points of Every 400 Hours
46
Replacing Fuel Filter Cartridge
47
Replacing Fuel Filter Element
47
Check Points of Every 500 Hours
48
Cleaning Water Jacket and Radiator Interior
48
Anti-Freeze
49
Replacing Fan Belt
49
Check Points of Every 1 or 2 Months
50
Recharging
50
Precaution for Operating a Quick Charger
50
Check Points of Every Year
51
Battery Specific Gravity
51
Replacing Air Cleaner Element
51
Check Points of Every 800 Hours
52
Valve Clearance
52
Check Points of Every 1500 Hours
53
Nozzle Spraying Condition
53
Fuel Injection Pressure
54
Valve Seat Tightness
55
Nozzle Holder
55
Check Points of Every 3000 Hours
56
Checking Turbocharger
56
Checking Injection Pump
57
Check Points of Every 2 Years
59
Replacing Intake Air Line
59
Replacing Battery
59
Replacing Radiator Hoses and Clamp Bands
59
Replacing Fuel Hoses and Clamp Bands
60
Changing Radiator Coolant
61
5 Special Tools
63
Diesel Engine Compression Tester
63
Oil Pressure Tester
63
Injection Pump Pressure Tester
64
Valve Guide Replacing Tool
64
Bushing Replacing Tools
65
Crankshaft Bearing 1 Replacing Tool
65
Flywheel Stopper
65
Auxiliary Socket for Fixing Crankshaft Sleeve
66
Socket Wrench for Crank Pulley Nut
66
Balancer Metal Replacing Tool
68
Idle Gear 2 Puller
70
Mechanism
71
Engine Body
72
Piston
72
Built-In Dynamic Balancer (Balancer Model Only
73
Half-Floating Head Cover
74
Bottom Bypass System
75
Cooling System
75
Fuel System
76
Governor
76
Boost Compensator
77
Turbocharger System
77
Servicing
78
Clean or Replace
79
Engine Body
79
Troubleshooting
79
Adjust S-27
80
Repair or Replace S-29
80
Replace
80
Use Specified Fuel 5 to
80
Electronic Governor
83
Servicing Specifications
85
Timing Gear
88
Tightening Torques for General Use Screws, Bolts and Nuts
97
Tightening Torques for Special Use Screws, Bolts and Nuts
98
Checking and Adjusting
99
Checking, Disassembling and Servicing
99
Compression Pressure
99
Engine Body
99
Adjust
102
Cooling System
102
Engine Oil Pressure
102
Fan Belt Tension
102
Lubricating System
102
Radiator Cap Air Leakage
103
Radiator Water Leakage
103
Thermostat Valve Opening Temperature
104
Fuel System
105
Injection Timing
105
Fuel Tightness of Pump Element
107
Fuel Tightness of Delivery Valve
109
Battery Voltage
114
Electrical System
114
Magnet Switch Continuity Test
116
Magnetic Switch Test
116
Motor Test
116
Alternator on Unit Test
117
Glow Plug Continuity
117
Glow Plug Lead Terminal Voltage
117
Compressor Side
118
Engine Stop Solenoid
118
Radial Clearance
118
Turbine Side
118
Turbocharger
118
Electronic Governor
119
Speed Sensor
119
Water Temperature Sensor
119
Oil Pressure Switch
120
Solenoid
121
Alternator
122
Glow Plug Harness
122
Speed Switch
122
Battery
123
Emergency Stop Switch
123
Slow down Switch
123
Air Cleaner, Muffler and Others
124
Disassembling and Assembling
124
Draining Oil and Coolant
124
External Components
124
Turbocharger
125
Cylinder Head and Valves
126
Injection Pipes
126
Nozzle Holder Assembly and Glow Plug
127
Nozzle Heat Seal Service Removal Procedure
128
Rocker Arm and Push Rod
128
Cylinder Head
129
Tappets
130
Thermostat Assembly
131
Valves
131
Water Pump Assembly
131
Gear Case and Timing Gears
132
Injection Pump
132
Governor Springs and Speed Control Plate
134
Fan Drive Pulley
136
Idle Gear 2 and Hydraulic Pump Base Assembly
137
Crankshaft Oil Slinger
138
Gear Case
138
Idle Gear
138
Camshaft and Balancer Shaft
139
Crank Gear
140
Fuel Camshaft and Fork Lever Assembly
140
Oil Pump
140
Oil Pan and Oil Strainer
141
Piston and Connecting Rod
141
Pistons
142
Piston Ring and Connecting Rod
144
Bearing Case Cover
146
Flywheel and Crankshaft
146
Main Bearing Case Assembly
148
Starter
149
Alternator
150
Cylinder Head and Valves
151
Servicing
151
Top Clearance
151
Cylinder Head Flaw
152
Cylinder Head Surface Flatness
152
Valve Recessing
153
Clearance between Valve Stem and Valve Guide
154
Replacing Valve Guide
154
Valve Seating
155
Correcting Valve and Valve Seat
156
Free Length and Tilt of Valve Spring
157
Valve Lapping
157
Valve Spring Setting Load
157
Oil Clearance between Rocker Arm and Rocker Arm Shaft
158
Oil Clearance between Tappet and Tappet Guide Bore
158
Push Rod Alignment
158
Idle Gear Side Clearance
159
Timing Gear Backlash
159
Camshaft Alignment
160
Camshaft Side Clearance
160
Cam Height
161
Oil Clearance of Camshaft Journal
162
Balancer Shaft Alignment
163
Balancer Shaft Side Clearance
163
Oil Clearance between Idle Gear Shaft and Idle Gear Bushing
163
Replacing Idle Gear Bushing
163
Oil Clearance of Balancer Shaft Journal
164
Piston and Connecting Rod
164
Piston Pin Bore I.D.
164
Connecting Rod Alignment
165
Oil Clearance between Piston Pin and Small End Bushing
165
Replacing Connecting Rod Small End Bushing
165
Piston Ring Gap
166
Clearance between Piston Ring and Groove
167
Crankshaft Alignment
168
Side Clearance of Crankshaft
168
Oil Clearance between Crankpin and Crankpin Bearing
169
Oil Clearance between Crankshaft Journal and Crankshaft Bearing
170
Replacing Crankshaft Bearing
170
Replacing Crankshaft Sleeve
172
Cylinder Wear
173
Correcting Cylinder
174
Clearance between Rotor and Cover
175
Oil Pump
175
Overrunning Clutch
175
Rotor Lobe Clearance
175
Starter
175
Commutator and Mica
176
Brush Wear
177
Armature Coil
178
Brush Holder
178
Field Coil
178
Alternator
179
Bearing
179
Rotor
179
Slip Ring
179
Stator
179
IC Regulator
180
Rectifier
180
4
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Kubota V2403-M-T Specifications
General
Brand
Kubota
Model
V2403-M-T
Category
Engine
Language
English
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